Sole assembly with thermoplastic polyurethane component thereon and  and method of manufacturing same

ABSTRACT

An article of footwear has a sole assembly that includes a midsole. The midsole has a bottom with a bottom surface, and an outer wall with a side surface. At least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is secured to the midsole. Specifically, a thermoplastic polyurethane outsole can be secured to the bottom surface of the midsole and a thermoplastic polyurethane toe bumper can be secured to the side surface of the midsole. Moreover, at least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is at least partially transparent. A method of manufacturing an article of footwear includes securing such a thermoplastic polyurethane outsole and/or a thermoplastic polyurethane toe bumper to the midsole.

TECHNICAL FIELD

The present teachings generally include a sole assembly for an articleof footwear, and a method of manufacturing an article of footwear.

BACKGROUND

Footwear typically includes a sole configured to be located under awearer's foot to space the foot away from the ground or floor surface.Soles can be designed to provide a desired level of cushioning. A solemay be an assembly that includes a midsole and an outsole. Athleticfootwear in particular sometimes utilizes polyurethane foam or otherresilient materials in the sole to provide cushioning.

SUMMARY

An article of footwear has a sole assembly that includes a midsole. Themidsole has a bottom with a bottom surface, and an outer wall with aside surface. At least one of a thermoplastic polyurethane outsole and athermoplastic polyurethane toe bumper is secured to the midsole.Specifically, a thermoplastic polyurethane outsole can be secured to thebottom surface of the midsole and a thermoplastic polyurethane toebumper can be secured to the side surface of the midsole. Moreover, thethermoplastic polyurethane outsole and/or the thermoplastic polyurethanetoe bumper is at least partially transparent. By use of an at leastpartially transparent thermoplastic polyurethane outsole or toe bumper,various aesthetic features can be achieved. For example, thethermoplastic polyurethane outsole or toe bumper can be dyed one or morecolors, a graphic can be laser-etched on an inward-facing or on anoutward-facing surface, or a polymeric film with a graphic appearingthereon can be secured to the thermoplastic polyurethane outsole or toebumper. As used herein, a “graphic” is a design that may include text,figures, or images. Because the thermoplastic polyurethane outsole ortoe bumper remains at least partially transparent, the color or colors,the laser-etched graphic, or the graphic on the polymeric film isvisible on the article of footwear.

The midsole may be but is not limited to rubber. If the midsole isrubber, a two-sided or double-coated adhesive film can be used to attachthe outsole or toe bumper to the midsole. The film has a carrier with afirst side and a second side. A first adhesive is on the first side, anda second adhesive is on the second side. The first adhesive is incontact with and is configured to bond to the rubber of the midsole. Thesecond adhesive is in contact with and is configured to bond to thethermoplastic polyurethane of the toe bumper.

The midsole may be configured to have a shape similar to a traditionalautoclave-type athletic shoe. For example, the midsole can have a sidewall forming the side surface, with the side wall generally orthogonalto the outsole. Such a configuration can be achieved whether the midsoleis a rubber component or is a bladder element formed from an upper andlower polymeric sheet.

A method of manufacturing an article of footwear includes securing atleast one of a thermoplastic polyurethane toe bumper and a thermoplasticpolyurethane outsole to a midsole. Depending on the material of themidsole, the securing may be by one of bonding and radio frequencywelding. For example, if the midsole is rubber, the securing may includeapplying a double-coated adhesive film so that a first side of thedouble-coated adhesive film bonds to the midsole and a second side ofthe double-coated adhesive film bonds to the toe bumper or the outsole.The method may include laser-etching a graphic on said at least one of atoe bumper and an outsole. The method may include dyeing the toe bumperand/or the outsole at least one color, or dyeing the toe bumper and/orthe outsole a first color on a first side and a second color on a secondside. Additionally, the method may include attaching a polymeric film tothe toe bumper and/or the outsole prior to securing the toe bumperand/or the outsole to the midsole. The polymeric film can have a graphicappearing thereon. Because the toe bumper and/or the outsole is an atleast partially transparent thermoplastic polyurethane, even if dyed,the laser-etched graphic and/or the graphic on the polymeric film isvisible.

With the variety of aesthetic features available with the use of thethermoplastic polyurethane outsole and/or the thermoplastic polyurethanetoe bumper, the method may include manufacturing the article of footwearaccording to a customer-selected visual characteristic, such as aparticular color or graphic. Accordingly, the method may includereceiving a customer selection of a visual characteristic of the toebumper and/or the outsole, and then providing an article of footwearwith the toe bumper and/or the outsole having the selected visualcharacteristic.

“A,” “an,” “the,” “at least one,” and “one or more” are usedinterchangeably to indicate that at least one of the item is present; aplurality of such items may be present unless the context clearlyindicates otherwise. All numerical values of parameters (e.g., ofquantities or conditions) in this specification, including the appendedclaims, are to be understood as being modified in all instances by theterm “about” whether or not “about” actually appears before thenumerical value. “About” indicates that the stated numerical valueallows some slight imprecision (with some approach to exactness in thevalue; approximately or reasonably close to the value; nearly). If theimprecision provided by “about” is not otherwise understood in the artwith this ordinary meaning, then “about” as used herein indicates atleast variations that may arise from ordinary methods of measuring andusing such parameters. In addition, a disclosure of a range is to beunderstood as specifically disclosing all values and further dividedranges within the range.

The terms “comprising,” “including,” and “having” are inclusive andtherefore specify the presence of stated features, steps, operations,elements, or components, but do not preclude the presence or addition ofone or more other features, steps, operations, elements, or components.Orders of steps, processes, and operations may be altered when possible,and additional or alternative steps may be employed. As used in thisspecification, the term “or” includes any one and all combinations ofthe associated listed items.

Those having ordinary skill in the art will recognize that terms such as“above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are useddescriptively for the figures, and do not represent limitations on thescope of the invention, as defined by the claims.

The above features and advantages and other features and advantages ofthe present teachings are readily apparent from the following detaileddescription of the best modes for carrying out the present teachingswhen taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view illustration of an article of footwearwith a sole assembly having an outsole and a toe bumper secured to amidsole.

FIG. 2 is a schematic illustration in perspective view showing thearticle of footwear of FIG. 1 with the toe bumper and the outsole.

FIG. 3 is a schematic cross-sectional illustration of the article offootwear of FIGS. 1 and 2 taken at lines 3-3 in FIG. 2.

FIG. 4 is a schematic illustration in perspective view showing athermoplastic polyurethane component for the article of footwear of FIG.1 or of FIG. 13 with a graphic laser-etched on an outward-facing side.

FIG. 5 is a schematic illustration in perspective view showing athermoplastic polyurethane component for the article of footwear of FIG.1 or of FIG. 13 with a graphic laser-etched on an inward-facing side.

FIG. 6 is a schematic illustration in perspective view showing athermoplastic polyurethane component for the article of footwear of FIG.1 or of FIG. 13 with a graphic laser-etched on an outward-facing sideand dyed two different colors.

FIG. 7 is a schematic illustration in perspective view showing athermoplastic polyurethane component for the article of footwear of FIG.1 or of FIG. 13 with a graphic laser-etched on an inward-facing side anddyed two different colors.

FIG. 8 is a schematic illustration in perspective view showing athermoplastic polyurethane component for the article of footwear of FIG.1 or of FIG. 13 with a polymeric film having a graphic thereon attachedto an inward-facing side.

FIG. 9 is a schematic illustration in exploded perspective view showingthe thermoplastic polyurethane component and the polymeric film of FIG.8.

FIG. 10 is a schematic illustration in perspective view showing athermoplastic polyurethane component for the article of footwear of FIG.1 or of FIG. 13 dyed two different colors and with a polymeric filmhaving a graphic thereon attached to an inward-facing side.

FIG. 11 is a schematic illustration in exploded perspective view showingthe thermoplastic polyurethane component and the polymeric film of FIG.10.

FIG. 12 is a schematic illustration in perspective view of adouble-coated adhesive film used to attach a toe bumper or an outsole tothe midsole of FIGS. 1 and 2.

FIG. 13 is a schematic side view illustration of an alternative articleof footwear with a sole assembly having a midsole that is a bladderelement and with an outsole and a toe bumper secured to the midsole.

FIG. 14 is a schematic illustration in perspective view showing thearticle of footwear of FIG. 13 with the toe bumper and the outsole.

FIG. 15 is a schematic illustration in perspective view showing an outersurface of a thermoformed upper polymeric sheet of the bladder element.

FIG. 16 is a schematic illustration in perspective view showing an innersurface of the thermoformed polymeric upper sheet of FIG. 15.

FIG. 17 is a flow diagram of a method of manufacturing the article offootwear of FIG. 1 or of FIG. 13.

DETAILED DESCRIPTION

Referring to the drawings, wherein like reference numbers refer to likecomponents throughout the views, FIG. 1 shows an article of footwear 10that has a sole assembly 12 with a midsole 14. As further describedherein, the midsole 14 is secured to a shoe upper 22, an outsole 24, anda toe bumper 26 are secured to the midsole 14. In the embodiment shown,the midsole 14 provides the general shape of a traditional athletic shoewith a rubber sole as manufactured according to an autoclave process.For example, the outer wall 44 of the midsole 14 surrounds a periphery68 of the upper 22 and has a side surface 45 generally orthogonal to theoutsole 24. However, other types of midsoles can be used within thescope of the present teachings. The midsole 14 has a bottom 31 with abottom surface 33. The midsole 14 extends the full length of the articleof footwear 10, and has a heel region 36, a midfoot region 38, and aforefoot region 40.

As indicated in FIG. 3, an inward-facing side 21 of the outsole 24 issecured to the bottom surface 33. An outward-facing side 25 of theoutsole 24 establishes a ground contact surface 35 shown in FIG. 2. Themidsole 14 also has an outer wall 44, which may also be referred to as aside wall. The outer wall 44 has an outward-facing side surface 45. Aninward-facing side 27 of the toe bumper 26 is secured to the sidesurface 45. An outward-facing side 29 of the toe bumper 26 has agraphical pattern 23 thereon. The graphic pattern 23 may be laser-etchedon the toe bumper 26. The side surface 45 is generally orthogonal to thebottom surface 33.

In the embodiment of FIGS. 1-3, the midsole 14 is rubber, and either orboth of the outsole 24, and the toe bumper 26 are an at least partiallytransparent thermoplastic polyurethane (TPU). In other embodiments, themidsole 14 can be a material other than rubber, and one or both of thetoe bumper 26 and the outsole 24 can be a material other than TPU. Forexample, the outsole 24 can be rubber. In the embodiment of FIGS. 1-3,the midsole 14 has a smooth texture, and is a first color. The outsole24 is a second color, and has a second texture which may be referred toas a corrugated texture, as a result of tread elements 47 that have azig-zag pattern, commonly referred to as a herringbone pattern. Forexample, in one embodiment, the midsole 14 is white and the outsole 24and toe bumper 26 are blue. If of a TPU material, the outsole 24 and toebumper 26 remain at least partially transparent even when dyed one ormore colors.

By use of a TPU outsole 24 and/or toe bumper 26, a variety of differentaesthetic options can be achieved while durability functions of theoutsole 24 and toe bumper 26 are also accomplished. These options areshown in FIGS. 4-11 by TPU components 120A-120F, any of which mayrepresent the toe bumper 26 and/or the outsole 24. Differentcombinations of the TPU components 120A-120F can be used for the toebumper 26 and the outsole 24. As further explained herein, a customermay select a visual characteristic or feature of either or both of thetoe bumper 26 and the outsole 24, and the article of footwear 10 canthen be manufactured and/or provided with the toe bumper 26 or outsole24 having the customer-selected visual characteristic.

FIG. 4 shows a transparent TPU component 120A that has a laser-etchedgraphic 123A on a first side 125A. A second side 127A does not have agraphic thereon. FIG. 5 shows a similar transparent TPU component 120Bthat has the laser-etched graphic 123A on a second side 127B. A firstside 125B does not have a graphic thereon. Because the TPU material isat least partially transparent, the laser-etched graphic 123A is visiblewhen viewed through the material of the component 120B from the firstside 125B.

When the material of the component 120A of FIG. 4 is used for the toebumper 26, the first side 125A is an outward-facing side, i.e.,outward-facing side 29 of FIG. 3, and the second side 127A is aninward-facing side secured to the midsole 14, correlating withinward-facing side 27 of FIG. 3. When the material of component 120A isused for the outsole 24, the first side 125A is an outward-facing side,i.e., outward-facing side 25 of FIG. 3, and the second side 127A is aninward-facing side secured to the midsole 14, correlating withinward-facing side 21 of FIG. 3. In each of these embodiments, thelaser-etched graphic 123A is on the outward-facing side.

When the material of the component 120B of FIG. 5 is used for the toebumper 26, the first side 125B is an outward-facing side, i.e.,outward-facing side 29 of FIG. 3, and the second side 127B is aninward-facing side secured to the midsole 14, correlating withinward-facing side 27 of FIG. 3. When the material of component 120B isused for the outsole 24, the first side 125B is an outward-facing side,i.e., outward-facing side 25 of FIG. 3, and the second side 127B is aninward-facing side secured to the midsole 14, correlating withinward-facing side 21 of FIG. 3. In each of these embodiments, thelaser-etched graphic 123A is on the inward-facing side 21 or 27.However, because the TPU material is transparent, the laser-etchedgraphic 123A is visible when looking through the toe bumper 26 or theoutsole 24 from the outward-facing side 29 or 25. In FIGS. 4 and 5, theedges of the TPU components 120A, 120B on portions facing away from theperspective view are shown with hidden lines for purposes of clarity inthe drawings. In FIG. 5, the graphic 123A is shown with hidden lines forpurposes of clarity in the drawings. It should be appreciated, however,that because the TPU material is transparent, the edges and the graphic123A shown in hidden lines are actually visible from the perspectiveshown in the drawings.

FIGS. 6 and 7 show embodiments of transparent TPU components 120C, 120Dthat combine laser-etching and dyeing. FIG. 6 shows a transparent TPUcomponent 120C that has a laser-etched graphic 123B on a first side125C. A second side 127C does not have a graphic thereon. Alternatively,both sides 125C, 127C may have the same or different laser-etchedgraphics thereon. FIG. 7 shows a similar transparent TPU component 120Dthat has a laser-etched graphic 123B on a second side 127D. A first side125D does not have a graphic thereon. Because the material istransparent, the laser-etched graphic 123B is visible when viewedthrough the material of the component 120D from the first side 125D. InFIGS. 6 and 7, the edges of the TPU components 120C, 120D on portionsfacing away from the perspective view are shown with hidden lines forpurposes of clarity in the drawings. In FIG. 7, the graphic 123B isshown with hidden lines for purposes of clarity in the drawings. Itshould be appreciated, however, that because the TPU material istransparent, the edges and the graphic 123B shown in hidden lines areactually visible from the perspective shown in the drawings.

The TPU component 120C of FIG. 6 is dyed a first color extending toapproximately a first portion T1 of the thickness T of the component120C. The TPU component is dyed a second color extending toapproximately a remaining portion T2 of the thickness T. Dyeing can beaccomplished in stages. First, the undyed TPU component 120C can beplaced with the first side 125C down in a first container of dye of thefirst color, with the dye in the container at a depth T1. The TPUcomponent 120C will remain in the first container until the dye of thefirst color is absorbed in the portion of the thickness T1. The TPUcomponent 120C can be allowed to dry, and then can be placed with thesecond side 127C face down in a second container of dye that is thesecond color, with the dye in the container at a depth T2. The TPUcomponent 120C will remain in the second container until the dye of thesecond color is absorbed in the portion of the thickness T2. The portiondyed the first color is untouched and unaffected by the dye of thesecond color. The TPU component 120D of FIG. 7 is dyed in an identicalmanner as described with respect to the TPU component 120C. The dyeingprocess can occur either before or after the laser-etching of thegraphic 123B on the first side 125C of the TPU component 120C, andeither before or after the laser-etching of the graphic 123B on thesecond side 127D of the TPU component 120D. When looking through thecomponent 120C or 120D from the first side 125C, 125D to the second side127C, 127D, the second color may affect the appearance as the components120C, 120D are at least partially transparent.

When the material of the component 120C of FIG. 6 is used for the toebumper 26, the first side 125C is an outward-facing side, i.e.,outward-facing side 29 of FIG. 3, and the second side 127C is aninward-facing side secured to the midsole 14, correlating withinward-facing side 27 of FIG. 3. When the material of component 120C isused for the outsole 24, the first side 125C is an outward-facing side,i.e., outward-facing side 25 of FIG. 3, and the second side 127C is aninward-facing side secured to the midsole 14, correlating withinward-facing side 21 of FIG. 3. In each of these cases, thelaser-etched graphic 123B is on the outward-facing side.

When the material of the component 120D of FIG. 7 is used for the toebumper 26, the first side 125D is an outward-facing side, i.e.,outward-facing side 29 of FIG. 3, and the second side 127D is aninward-facing side secured to the midsole 14, correlating withinward-facing side 27 of FIG. 3. When the material of component 120D isused for the outsole 24, the first side 125D is an outward-facing side,i.e., outward-facing side 25 of FIG. 3, and the second side 127D is aninward-facing side secured to the midsole 14, correlating withinward-facing side 21 of FIG. 3. In each of these cases, thelaser-etched graphic 123B is on the inward-facing side 21 or 27.However, because the TPU material is transparent, the laser-etchedgraphic 123B is visible when looking through the toe bumper 26 or theoutsole 24 from the outward-facing side 29 or 25.

FIG. 8 shows a TPU component 120E that is dyed a single color throughoutits thickness T. Additionally, the TPU component 120E has a polymericfilm 129 adhered or otherwise secured to a second side 127E thereof. Thepolymeric film 129 has a graphic 131, such as a graphical design, textor image, thereon. The TPU component is transparent even when dyed.Therefore the graphic 131 of the polymeric film 129 is visible throughthe TPU component 120E even when viewed from the first side 125E. FIG. 9shows the film 129 being moved toward the TPU component 120E in thedirection of arrows 133. An upper surface 135 of the polymeric film 129can have adhesive thereon.

When the material of the component 120E of FIG. 8 is used for the toebumper 26, the first side 125E is an outward-facing side, i.e.,outward-facing side 29 of FIG. 3, and the second side 127E is aninward-facing side secured to the midsole 14, correlating withinward-facing side 27 of FIG. 3. When the material of component 120E isused for the outsole 24, the first side 125E is an outward-facing side,i.e., outward-facing side 25 of FIG. 3, and the second side 127E is aninward-facing side secured to the midsole 14, correlating withinward-facing side 21 of FIG. 3. In each of these cases, the polymericfilm 129 with the graphic 131 is on the inward-facing side 21 or 27.However, because the TPU material is transparent, the graphic 131 isvisible when looking through the toe bumper 26 or the outsole 24 fromthe outward-facing side 29 or 25. In FIGS. 8 and 9, the edges of the TPUcomponent 120E on portions facing away from the perspective view areshown with hidden lines for purposes of clarity in the drawings. In FIG.8, the graphic 131 on the film 129 is shown with hidden lines forpurposes of clarity in the drawings. It should be appreciated, however,that because the TPU material is transparent, the edges and the graphic131 shown in hidden lines are actually visible from the perspectiveshown in the drawings.

FIG. 10 shows a TPU component 120F that is dyed two different colorsaccording to the dyeing process described with respect to FIG. 6. TheTPU component 120F is dyed a first color extending to approximately afirst portion T1 of the thickness T of the component 120F. The TPUcomponent 120F is dyed a second color extending to approximately aremaining portion T2 of the thickness T. Additionally, the TPU component120F has the polymeric film 129 described with respect to FIG. 8 adheredor otherwise secured to a second side 127F thereof. The polymeric film129 has the graphic 131 thereon. The film 129 can be secured such as byadhesives, as described with respect to FIG. 9, after the dyeingprocess. The TPU component 120F is transparent even when dyed. Thereforethe graphic 131 of the polymeric film 129 is visible through the TPUcomponent 120F even when viewed from the first side 125F. FIG. 11 showsthe film 129 being moved toward the TPU component 120F in the directionof arrows 133. An upper surface 135 of the polymeric film 129 can haveadhesive thereon.

When the material of the component 120F of FIG. 10 is used for the toebumper 26, the first side 125F is an outward-facing side, i.e.,outward-facing side 29 of FIG. 3, and the second side 127F is aninward-facing side secured to the midsole 14, correlating withinward-facing side 27 of FIG. 3. When the material of component 120F isused for the outsole 24, the first side 125F is an outward-facing side,i.e., outward-facing side 25 of FIG. 3, and the second side 127F is aninward-facing side secured to the midsole 14, correlating withinward-facing side 21 of FIG. 3. In each of these cases, the polymericfilm 129 with the graphic 131 is on the inward-facing side 21 or 27.However, because the TPU material is transparent, the graphic 131 isvisible when looking through the toe bumper 26 or the outsole 24 fromthe outward-facing side 29 or 25. In FIGS. 10 and 11, the edges of theTPU component 120F on portions facing away from the perspective view areshown with hidden lines for purposes of clarity in the drawings. In FIG.10, the graphic 131 on the film 129 is shown with hidden lines forpurposes of clarity in the drawings. It should be appreciated, however,that because the TPU material is transparent, the edges and the graphic131 shown in hidden lines are actually visible from the perspectiveshown in the drawings.

FIG. 12 shows double-coated adhesive film 150 that can be used to attacha TPU component to a rubber component. The double-coated adhesive film150 is used to attach the TPU toe bumper 26 to the side surface 45 ofthe outer wall 44 of the rubber midsole 14, and is used to attach theTPU outsole 24 to the bottom surface 33 of the midsole 14. Specifically,the double-coated adhesive film 150 has a carrier 152. The carrier 152has a first side 154 and a second side 156. A first adhesive 158 isapplied on the first side 154. A second adhesive 160 is applied on thesecond side 156. The first adhesive 158 is specifically formulated tobond to rubber. The second adhesive 160 is specifically formulated tobond to thermoplastic polyurethane such as during heating by thermalbonding. The double-coated adhesive film 150 is placed between the toebumper 26 and the midsole 14 so that the first adhesive 158 is incontact with and bonds to the rubber of the midsole 14 on the side wall44. The second adhesive 160 is in contact with and bonds to thethermoplastic polyurethane of the toe bumper 26 on the inward-facingside of the toe bumper 26. Similarly, the double-coated adhesive film150 is used to bond the outsole 24 to the bottom surface 33 of themidsole 14 by placing the first adhesive 158 in contact with the midsole14 and the second adhesive 160 in contact with the outsole 24. Thedouble-coated adhesive film 150 can be applied first to the midsole 14and then to the respective TPU component, toe bumper 26 or outsole 24,or the double-coated adhesive film 150 can be applied first to therespective TPU component, toe bumper 26 or outsole 24, and then to themidsole 14. The double-coated adhesive film 150, including the adhesives158, 160 and the carrier 152, is transparent. Accordingly, thedouble-coated adhesive film 150 does not affect the aesthetics of thetoe bumper 26 or the outsole 24.

FIGS. 13 and 14 show another article of footwear 210 to which the TPUtoe bumper 26 and the TPU outsole 24 can be secured. The article offootwear 210 has a sole structure 212 with a midsole 214 that is afull-length bladder element rather than a rubber midsole. The midsole214 is also referred to as a bladder element 214.

The bladder element 214 is a fluid-filled, airtight chamber, as furtherdescribed herein. The bladder element 214 can be inflated and canresiliently retain a fluid such as air or another gas, and can be at anambient pressure or pressurized. If the bladder element 214 is inflatedwith air, it may be referred to as an airbag.

The bladder element 214 is formed from two polymeric sheets, including afirst polymeric sheet 16, and a second polymeric sheet 18. The firstpolymeric sheet 16 is also referred to herein as an upper polymericsheet 16, and the second polymeric sheet 18 is also referred to hereinas a lower polymeric sheet 18. The polymeric sheets 16, 18 are attachedto one another as described herein to define a sealed interior cavity 20that retains the fluid. FIG. 15 shows a tube 17 formed in the upperpolymeric sheet 16. The tube 17 is used to fill the bladder element 214.The opening in the tube 17 is then plugged and the tube 17 is trimmed.As further described herein, the bladder element 214 is cooperativelyconfigured to interfit with the footwear upper 22, the outsole 24, andthe optional toe bumper 26 to provide the general shape of a traditionalathletic shoe with a rubber sole as manufactured according to anautoclave process. In other embodiments, the article of footwear 210could be for a dress shoe, a work shoe, a sandal, a slipper, a boot, orany other category of footwear. The bladder element 214 providesdesirable resiliency and cushioning characteristics and may be lighterin weight than a traditional rubber sole. Moreover, as the bladderelement 214, the outsole 24, and the toe bumper 26 can be formed from atleast partially transparent materials, the article of footwear 210 hasunique characteristics, such as the visibility of the shoe upper 22through the bladder element 214 from the exterior of the article offootwear 10.

Referring to FIG. 15, the upper polymeric sheet 16 has an outer surface30 that defines a downwardly-extending recess 32. More specifically, aportion of the outer surface 30 is an upward-facing surface 34 that isgenerally the shape of a human foot. The surface 34 is configured as afoot support surface with a heel region 36, a midfoot region 38, and aforefoot region 40 generally correlating with a heel, an arch, and aforefoot of a human foot. The foot need not directly contact theupward-facing surface 34, but is supported by the upward-facing surface34. For purposes of discussion, the heel region 36, the midfoot region38, and the forefoot region 40 are defined as the rearmost third, themiddle third, and the foremost third of the upward-facing surface 34.Heel region 36 generally includes portions of the upper polymeric sheet16 corresponding with rear portions of a human foot of a sizecorresponding with the article of footwear 210, including the calcaneusbone. Forefoot region 40 generally includes portions of the upperpolymeric sheet 16 corresponding with the toes and the joints connectingthe metatarsals with the phalanges of a human foot of a sizecorresponding with the article of footwear 210. Midfoot region 38generally includes portions of the upper polymeric sheet 16corresponding with an arch area of a human foot of a size correspondingwith the article of footwear 210. In light of the upward-facing surface34 having a heel region 36, a midfoot region 38, and a forefoot region40, the bladder element 214 can be referred to as a full-length bladderelement, as the heel region 36, midfoot region 38, and forefoot region40 together extend the full length of a human foot having dimensions forwhich the article of footwear 210 is sized.

In the embodiment shown, the upper polymeric sheet 16 is formed from asingle, flat sheet, such as by thermoforming, to attain the relativelycomplex, contoured shape shown in FIGS. 15 and 16. The upper polymericsheet 16 has an inner wall portion 42, a peripheral outer wall portion244, and a ridge 46 between the inner wall portion 42 and the outer wallportion 244. The ridge 46 forms the uppermost extent of the sheet 16.The inner wall portion 42 extends generally downward to theupward-facing surface 34 so that the inner wall portion 42 and theupward-facing surface 34 together define the recess 32. The outer wallportion 244 extends generally downward from the ridge 46 further thanthe recess 32 and the inner wall portion 42, so that a continuousterminal edge 48 of the outer wall portion 244 is below a lowest extentof the recess 32, and extends around an entire periphery of the recess32. In other words, the portion of the upper polymeric sheet 16 formingthe upward-facing surface 34 is elevated relative to the edge 48 in theassembled article of footwear 210. The outer wall portion 244 is alsoreferred to as an outer wall, a side wall, or a sidewall portion.

The bladder element 214 also includes the lower polymeric sheet 18attached to the upper polymeric sheet 16 by bonding at a flange 106 nearthe terminal edge 48 of the outer wall portion 244 as further describedherein. The upper and lower polymeric sheets 16, 18 define the interiorcavity 20. An inner surface of the lower polymeric sheet 18 is joined toan inner surface of the upper polymeric sheet 16 at multiple bonds 60extending transversely and only partway across the interior cavity 20from a medial side 62 of the outer wall portion 244 to a lateral side 64of the outer wall portion 244, as shown in FIG. 14. As used herein, alateral side of a component for an article of footwear 210, such as thelateral side 64 of the outer wall portion 244 of the upper polymericsheet 16, is a side that corresponds with an outside area of the foot ofthe wearer of the article of footwear 10 that is generally further fromthe other foot of the wearer (i.e., the side closer to the fifth toe ofthe wearer). The fifth toe is commonly referred to as the little toe. Amedial side of a component for an article of footwear, such as themedial side 62 of the outer wall portion 244 of the upper polymericsheet 16, is the side that corresponds with an inside area of the footon which the article of footwear 210 is worn and that is generallycloser to the other foot of the wearer (i.e., the side closer to thehallux of the foot of the wearer). The hallux is commonly referred to asthe big toe.

The recess 32, the ridge 46, and the outer wall portion 244 define aninverted channel 65 at the inner surface 51 of the upper polymeric sheet16. The inverted channel 65 is part of the interior cavity 20. Becausethe bonds 60 do not extend completely between the lateral side 64 of theouter wall portion 244 and the medial side 62 of the outer wall portion244, the inverted channel 65 is in fluid communication with the interiorcavity 20 and is a peripheral portion of the interior cavity 20.

The upper polymeric sheet 16 and the lower polymeric sheet 18 are atleast partly thermoplastic polyurethane. Examples of polymer materialsfor the bladder element 214 include thermoplastic polyurethane,polyester, polyester polyurethane, and polyether polyurethane. Moreover,each of the polymeric sheets 16, 18 of the bladder element 214 can beformed of layers of different materials. In one embodiment, the sheets16, 18 of the bladder element 214 are each formed from thin films havingone or more thermoplastic polyurethane (TPU) layers with one or morebarrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) thatis impermeable to the pressurized fluid contained therein as disclosedin U.S. Pat. No. 6,082,025 to Bonk et al., which is incorporated byreference in its entirety. The polymeric sheets 16, 18 may also beformed from a material that includes alternating layers of thermoplasticpolyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S.Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al. which areincorporated by reference in their entireties. Alternatively, the layersmay include ethylene-vinyl alcohol copolymer, thermoplasticpolyurethane, and a regrind material of the ethylene-vinyl alcoholcopolymer and thermoplastic polyurethane. The polymeric sheets 16, 18 ofthe bladder element 214 may also be flexible microlayer membranes thatinclude alternating layers of a gas barrier material and an elastomericmaterial, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonket al. which are incorporated by reference in their entireties.Additional suitable materials for the bladder element 214 are disclosedin U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, which areincorporated by reference in their entireties. Further suitablematerials for the bladder element 214 include thermoplastic filmscontaining a crystalline material, as disclosed in U.S. Pat. Nos.4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyesterpolyol, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and6,321,465 to Bonk et al. which are incorporated by reference in theirentireties.

In selecting materials for the bladder element 214, engineeringproperties such as tensile strength, stretch properties, fatiguecharacteristics, dynamic modulus, and loss tangent can be considered.The thicknesses of polymeric sheets 16, 18 used to form the bladderelement 214 can be selected to provide these characteristics. Thebladder element 214 is resilient and provides cushioning and flexibilitythat can be tuned such as by selecting a level of pressurization. In theembodiment shown in FIG. 13, the bladder element 214 is at ambientpressure. Optionally, tensile members and/or reinforcing structures canbe integrated with the bladder element 214 to provide desiredresponsiveness, such as disclosed in U.S. Pat. No. 4,906,502 to Rudy etal., and U.S. Pat. No. 8,061,060 to Swigart et al., which areincorporated by reference in their entireties.

Referring to FIG. 13, the footwear upper 22 has a lower surface 66secured to the upper surface 34 of the upper polymeric sheet 16 in therecess 32. The footwear upper 22 is also secured to the inner wallportion 42 shown in FIG. 15. The outer wall portion 244 surrounds aperiphery 68 of the footwear upper 22. The periphery 68 of the footwearupper 22 is indicated in FIG. 13. Stated differently, the footwear upper22 is nested in the recess 32 inward of the inner wall portion 42. Theupper polymeric sheet 16 is at least partially transparent. A lowerextent of the footwear upper 22 is thus visible from an exterior of thearticle of footwear 210 through the outer wall portion 244 and the innerwall portion 42 to the nested footwear upper 22.

Like the upper polymeric sheet 16, the lower polymeric sheet 18 is alsoan at least partially transparent material. The outsole 24 provides theground contact surface 74 of the article of footwear 210, and can bethermoplastic polyurethane with a greater hardness and thickness thanthe lower polymeric sheet 18 to provide durability, traction andabrasion resistance. An upper surface of the outsole 24 is secured to alower surface of the lower polymeric sheet 18 after bladder element 214is formed and inflated. The outsole 24 can be configured so that when itis secured to the lower polymeric sheet 18, the peripheral edge of theoutsole 24 is substantially perpendicular to the outer wall portion 244.The outsole 24 is an at least partially transparent thermoplasticpolyurethane. In this case, the outsole 24 is secured to the bladderelement 214 with adhesives or by radio frequency welding. Alternatively,the outsole 24 can be a rubber material, in which case the double-coatedadhesive film 150 of FIG. 12 is used to secure the outsole 24 to thebladder element 214. The pattern of the bonds 60 of the lower polymericsheet 18 to the upper polymeric sheet 16 is visible through the outsole24. The pattern of the bonds 60 may be selected to serve both amechanical function and to be aesthetically pleasing through the outsole24.

The optional toe bumper 26 is secured to a portion of the upperpolymeric sheet 16 that is the outward-facing surface 78 of the outerwall portion 244. Specifically, the toe bumper 26 is secured to theoutward-facing surface 78 at the outer wall portion 244 adjacent theforefoot region 40. Like the outsole 24, the toe bumper 26 may also bean at least partially transparent material, and can be a thermoplasticpolyurethane with a greater hardness and thickness than the lowerpolymeric sheet 18 to provide durability and abrasion resistance. Inthis case, the toe bumper 26 is secured to the bladder element 214 withadhesives or by radio frequency welding.

The thermoplastic polyurethane material used for the outsole 24 and/orthe toe bumper 26 can be any of the materials of TPU components120A-120F, with laser-etching, dyeing, and polymeric film 129 with agraphic 131, or with combinations of these aesthetic features, asdescribed herein. As further explained herein, a customer may select avisual characteristic or feature of either or both of the toe bumper 26and the outsole 24, and the article of footwear 210 can then bemanufactured and/or provided with the toe bumper 26 or outsole 24 havingthe customer-selected visual characteristic.

FIG. 17 is a flow diagram of a method 300 of manufacturing an article offootwear, such as article of footwear 10 or 210, with a TPU toe bumper26 and/or a TPU outsole 24. Optionally, the article of footwear 10 or210 can be made to order with one or more visual characteristicsaccording to a specifically indicated customer preference. In thisinstance, the method 300 can include step 302, receiving a customerselection of a visual characteristic of said at least one of a toebumper 26 and an outsole 24. The visual characteristic, for example, canbe a color of which all or a portion of the TPU toe bumper and/oroutsole 24 is to be dyed, a graphic to be laser-etched on the TPU toebumper 26 and/or on the outsole 24, or a graphic on a polymeric film 129to be attached to the TPU toe bumper 26 and/or outsole 24.

In step 304, the article of footwear 10 or 210 is provided with a TPUtoe bumper 26 and/or outsole 24, which are according to the customerselected visual characteristic if the method 300 includes step 302, or,otherwise, are according to another production decision.

The article of footwear 10 or 210 provided in step 304 results from oneor more substeps 306-316. In step 306, the TPU toe bumper 26 and/oroutsole 24 is secured to the midsole 14 or 214, respectively. In thecase of a rubber midsole 14, the securing step 306 may include sub-step308, in which the TPU toe bumper 26 and/or outsole 24 is bonded to themidsole 14 in step 308, such as with the double-coated adhesive film150. In the case of the polymeric bladder element 214 as the midsole,the securing step 306 may include sub-step 310, in which the TPU toebumper 26 and/or outsole 24 is secured to the midsole 214 by radiofrequency welding.

Optionally, the article of footwear 10 or 210 is provided with a visualcharacteristic, such as may be received from a customer in step 302. Forexample, in sub-step 312, a graphic such as 123A or 123B is laser-etchedon the toe bumper 26 and/or outsole 24. Additionally or alternatively,in sub-step 314, the toe bumper 26 and/or outsole 24 can be dyed one ormore colors, as described with respect to TPU components 120C, 120D,120E, and 120F. Still further, in sub-step 316, a polymeric film 129with a graphic appearing thereon, such as polymeric film 150 withgraphic 31, is attached to the toe bumper 26 and/or the outsole 24 insub-step 316.

Accordingly, the articles of footwear 10 or 210 and the method 300enable a wide variety of aesthetically-pleasing visual characteristicswith the use of TPU toe bumpers and/or outsoles.

While the best modes for carrying out the many aspects of the presentteachings have been described in detail, those familiar with the art towhich these teachings relate will recognize various alternative aspectsfor practicing the present teachings that are within the scope of theappended claims.

What is claimed is:
 1. A sole assembly for an article of footwearcomprising: a midsole having a bottom with a bottom surface, and havingan outer wall with a side surface; and at least one of a thermoplasticpolyurethane outsole secured to the bottom surface of the midsole and athermoplastic polyurethane toe bumper secured to the side surface of themidsole; wherein said at least one of a thermoplastic polyurethaneoutsole and a thermoplastic polyurethane toe bumper is at leastpartially transparent.
 2. The sole assembly of claim 1, wherein theoutsole has an inward-facing side secured to the bottom surface of themidsole and an outward-facing side establishing a ground contactsurface; and wherein the outsole has a laser-etched graphic on theoutward-facing side.
 3. The sole assembly of claim 1, wherein theoutsole has an inward-facing side secured to the bottom surface of themidsole; and wherein the outsole has a laser-etched graphic on theinward-facing side.
 4. The sole assembly of claim 1, wherein the toebumper has an inward-facing side secured to the side surface of themidsole and an outward-facing side; and wherein the toe bumper has alaser-etched graphic on the outward-facing side.
 5. The sole assembly ofclaim 1, wherein the toe bumper has an inward-facing side secured to theside surface of the midsole; and wherein the toe bumper has alaser-etched graphic on the inward-facing side.
 6. The sole assembly ofclaim 1, wherein said at least one of the outsole and the toe bumper hasan inward-facing side and an outward-facing side; and wherein said atleast one of the outsole and the toe bumper is dyed a first color on theinward-facing side and a second color on the outward-facing side.
 7. Thesole assembly of claim 6, wherein said at least one of the outsole andthe toe bumper has a thickness; wherein said at least one of the outsoleand the toe bumper is dyed a first color extending to approximately afirst portion of the thickness; and wherein said at least one of theoutsole and the toe bumper is dyed a second color extending toapproximately a remaining portion of the thickness.
 8. The sole-assemblyof claim 6, wherein said at least one of the outsole and the toe bumperhas a laser-etched graphic on the outward-facing side.
 9. Thesole-assembly of claim 6, wherein said at least one of the outsole andthe toe bumper has a laser-etched graphic on the inward-facing side. 10.The sole-assembly of claim 6, further comprising: a polymeric film witha graphic appearing thereon; wherein the polymeric film is attached tosaid at least one of the outsole and the toe bumper.
 11. The soleassembly of claim 10, wherein said at least one of the outsole and thetoe bumper has an inward-facing side and an outward-facing side; andwherein the polymeric film is attached to the inward-facing side and thegraphic is visible through said at least one of the outsole and the toebumper.
 12. The sole assembly of claim 11, wherein said at least one ofthe outsole and the toe bumper is dyed a first color on theinward-facing side and a second color on the outward-facing side. 13.The sole assembly of claim 1, wherein the midsole is rubber.
 14. Thesole assembly of claim 13, further comprising: a double-coated adhesivefilm attaching the toe bumper to the midsole; wherein the film has: acarrier with a first side and a second side; a first adhesive on thefirst side; a second adhesive on the second side; wherein the firstadhesive is in contact with and configured to bond to the rubber of themidsole; and wherein the second adhesive is in contact with andconfigured to bond to the thermoplastic polyurethane of the toe bumper.15. The sole assembly of claim 13, further comprising: a double-coatedadhesive film attaching the outsole to the midsole; wherein the filmhas: a carrier with a first side and a second side; a first adhesive onthe first side; a second adhesive on the second side; wherein the firstadhesive is in contact with and configured to bond to the rubber of themidsole; and wherein the second adhesive is in contact with andconfigured to bond to the thermoplastic polyurethane of the outsole. 16.The sole assembly of claim 1, wherein the midsole is a color differentthan a color of said at least one of the outsole and the toe bumper. 17.The sole assembly of claim 1, wherein the midsole has a first texture;and wherein said at least one of the outsole and the toe bumper has asecond texture different than the first texture.
 18. The sole assemblyof claim 1, wherein the outsole has a series of tread elements arrangedto extend laterally in a zig-zag pattern.
 19. The sole assembly of claim1, wherein the outer wall defines a periphery of the sole assembly; andwherein the outer wall and the bottom surface are substantiallyorthogonal.
 20. The sole assembly of claim 19, in combination with afootwear upper; and wherein the outer wall surrounds a periphery of thefootwear upper.
 21. The sole assembly of claim 1, wherein the midsole isa bladder element having: a first polymeric sheet; wherein the outerwall is a peripheral portion of the first polymeric sheet; a secondpolymeric sheet attached to the first polymeric sheet at the outer wallsuch that the first and second polymeric sheets define an interiorcavity; and wherein the second polymeric sheet defines the bottom andthe bottom surface of the midsole.
 22. A sole assembly for an article offootwear comprising: a midsole having a bottom with a bottom surface,and having an outer wall with a side surface; a thermoplasticpolyurethane outsole secured to the bottom surface; a thermoplasticpolyurethane toe bumper secured to the side surface; wherein the outsoleand the toe bumper are at least partially transparent; wherein at leastone of the outsole and the toe bumper has a laser-etched graphicthereon; wherein at least one of the outsole and the toe bumper has athickness and is dyed a first color extending to approximately a firstportion of the thickness; and wherein said at least one of the outsoleand the toe bumper is dyed a second color extending to approximately aremaining portion of the thickness.
 23. The sole assembly of claim 22,wherein the midsole is rubber; and further comprising: a double-coatedadhesive film attaching the outsole to the midsole; wherein the filmhas: a carrier with a first side and a second side; a first adhesive onthe first side; a second adhesive on the second side; wherein the firstadhesive is in contact with and configured to bond to the rubber of themidsole; and wherein the second adhesive is in contact with andconfigured to bond to the thermoplastic polyurethane of the outsole. 24.The sole assembly of claim 22, further comprising: a polymeric film witha graphic appearing thereon; wherein the polymeric film is attached toone of the outsole and the toe bumper
 25. A method of manufacturing anarticle of footwear, comprising: securing at least one of a toe bumperand an outsole to a midsole; wherein said at least one of the toe bumperand the outsole is thermoplastic polyurethane.
 26. The method of claim25, wherein said securing includes: applying a double-coated adhesivefilm so that a first side of the double-coated adhesive film bonds tothe midsole and a second side of the double-coated adhesive film bondsto said at least one of a toe bumper and an outsole.
 27. The method ofclaim 25, wherein said securing is by one of bonding and radio frequencywelding.
 28. The method of claim 25, further comprising: laser-etching agraphic on said at least one of a toe bumper and an outsole.
 29. Themethod of claim 25, further comprising: dyeing said at least one of atoe bumper and an outsole at least one color.
 30. The method of claim29, wherein said dyeing said at least one of a toe bumper and an outsoleincludes dyeing a first color on a first side of said at least one of atoe bumper and an outsole and dying a second color on a second side ofsaid at least one of a toe bumper and an outsole.
 31. The method ofclaim 25, further comprising: attaching a polymeric film to said atleast one of a toe bumper and an outsole; wherein the polymeric film hasa graphic appearing thereon.
 32. The method of claim 25, furthercomprising: receiving a customer selection of a visual characteristic ofsaid at least one of a toe bumper and an outsole; providing an articleof footwear with said at least one of a toe bumper and an outsole;wherein said at least one of a toe bumper and an outsole has said visualcharacteristic.
 33. The method of claim 32, wherein the visualcharacteristic is one of a color and a graphic.